FUEL INJECTOR(for Direct Injection)

INSTALL FUEL INJECTOR SEAL

*a Area to be Cleaned

Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector set and its grooves.
Note
- Do not clean the tip of the fuel injector set.
- Do not use a wire brush to clean the fuel injector set.
- If a fuel injector set is dropped or the tip of a fuel injector set is struck, replace it with a new one.
*a SST (Guide)

*b Chamfer

Apply engine oil to the fuel injector set contact surface of SST (guide). Then attach SST (guide) to the fuel injector set with the chamfer facing the tip of the fuel injector set as shown in the illustration.

SST

09260-39021 ( 09261-03020 )

*1	Fuel Injector Seal
*a	SST (Holder)
*b	Correct
*c	Incorrect

Install a new fuel injector seal to SST (holder).

SST: 09260-39021 ( 09261-03011 )

Note

Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal and correcting this problem is very complicated.

*a SST (Holder)

*b SST (Guide)

Install SST (holder) with fuel injector seal to the tip of the fuel injector set. Slide the fuel injector seal downward into the fuel injector set groove (fuel injector set connector side) with your fingers as shown in the illustration.

SST

09260-39021 ( 09261-03011, 09261-03020 )

Tech Tips

Check that the fuel injector seal covers the circumference of the fuel injector set groove as shown in the illustration.
*a SST (Guide)

Slowly slide SST (guide) toward the tip of the fuel injector set. When the fuel injector set contact surface of SST (guide) aligns with the fuel injector seal (fuel injector set tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the fuel injector seal into the fuel injector set groove.

SST

09260-39021 ( 09261-03020 )

Note

Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector set groove. Replace the fuel injector seal if it becomes damaged.
Tech Tips
- Set SST (guide) so that its bottom surface and the fuel injector seal are flush.
- If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the fuel injector set little by little.

*a	Normal
*b	Protruding
*c	Deformed
*d	Correct
*e	Incorrect

After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the fuel injector set groove.

Note

If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

INSTALL FUEL INJECTOR SET

Tech Tips

Perform "Inspection After Repair" after replacing the fuel injector set.

w/ Canister Pump Module:

Click here
w/o Canister Pump Module:

Click here

*1	Fuel Injector Set
*2	C-ring
*3	Injector Vibration Insulator
*a	Tapered Side

Install a new injector vibration insulator and a new C-ring to the fuel injector set.

Note

Install the injector vibration insulator by aligning it with the tapered side of the fuel injector set.
Check that the C-ring is securely fit into the groove of the fuel injector set.

Install a new O-ring and new No. 1 fuel injector back-up ring to the fuel injector set as shown in the illustration.

Note

Check that there is no foreign matter or damage on the O-ring groove of the fuel injector set.
Check that the No. 1 fuel injector back-up ring is installed in the correct direction.
Make sure that the No. 1 fuel injector back-up ring and O-ring are installed in the correct order.
Check that the alignment openings of the fuel injector back-up rings are not overlapped or stretched as shown in the illustration.
After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

*1	No. 1 Fuel Injector Back-up Ring	*2	O-ring
*a	No. 1 Fuel Injector Back-up Ring Opening	*b	Overlapped
*c	Stretched	*d	Correct
*e	Incorrect	-	-

*1	Fuel Injector Set
*2	No. 3 Fuel Injector Back-up Ring
*a	Notch

Set a new No. 3 fuel injector back-up ring so that it is level as shown in the illustration, push in the fuel injector set and install the No. 3 fuel injector back-up ring.

Note

Make sure that the No. 3 fuel injector back-up ring is oriented correctly.
After installing the O-ring, make sure there is no damage or foreign matter.

Install the nozzle holder clamp to the fuel injector set.

*a	Protrusion
*b	Positioning Hole
	No Gap

Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe sub-assembly and insert the fuel injector set.

Note

Make sure that there is no foreign matter or damage inside the fuel injector set installation holes (fuel delivery pipe sub-assembly).
Do not get gasoline on the O-rings or inside the installation holes.
If the fuel injector set is difficult to insert, apply new engine oil to the chamfered part of the fuel injector set installation hole of the fuel delivery pipe sub-assembly. Be careful as it is easier for the fuel injector set to fall out of the fuel delivery pipe sub-assembly in this case.

Keep the fuel injector set straight when inserting it into the fuel delivery pipe sub-assembly.

*1	O-Ring	*2	Fuel Delivery Pipe Sub-assembly
*a	CORRECT	*b	INCORRECT

Check that there is no gap between the fuel delivery pipe sub-assembly and the nozzle holder clamp.

*a	QR Code
*b	Flow Classification Number

w/ GPF:

Install 4 fuel injector sets with the same flow classification number (the number to the left of the QR code is 1 to 9).

w/o GPF:

Install 4 fuel injector sets with the same flow classification number (the number to the left of the QR code which is 1, 2 or 3).

INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Apply lubricant to the fuel injector set installation hole.
*a Nut can be attached

Insert the stud bolt into the fuel delivery pipe sub-assembly until the screw threads protrude enough so that a nut can be attached.
Note
- If a fuel injector set is dropped or the tip of a fuel injector set is struck, replace it with a new one.
- Check that there is no foreign matter or damage on the fuel injector set installation holes of the fuel delivery pipe sub-assembly.
- When inserting the fuel delivery pipe sub-assembly, push it in evenly without tilting it.
Bolt

Nut

Install the fuel delivery pipe sub-assembly by uniformly tightening the 3 bolts and 2 nuts in several steps in the order shown in the illustration.

Torque:

34 N*m { 347 kgf*cm, 25 ft.*lbf }

Note

Make sure that there is no oil on the bolt threads and nut.
Connect the sensor wire with the bolt.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Connect the connector to the fuel pressure sensor.
Connect the 4 connectors to the fuel injector sets.
Install the sensor wire to the fuel delivery pipe sub-assembly with the 2 bolts.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }

INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here

INSTALL INTAKE MANIFOLD

Click here

INSPECT FOR FUEL LEAK

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PERFORM INITIALIZATION

Perform "Inspection After Repair" after replacing the fuel injector set.
- w/ Canister Pump Module:
  
  Click here
- w/o Canister Pump Module:
  
  Click here

*a	SST (Guide)
*b	Chamfer

	Bolt
	Nut

FUEL INJECTOR(for Direct Injection) INSTALLATION